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Biomass Or Glycerol to Biofuels University of Pennsylvania ScholarlyCommons Department of Chemical & Biomolecular Senior Design Reports (CBE) Engineering 4-2010 BIOMASS OR GLYCEROL TO BIOFUELS Jeanne Ho University of Pennsylvania Joseph Luchtan University of Pennsylvania Andrew Perlman University of Pennsylvania Andrew Solute University of Pennsylvania Follow this and additional works at: https://repository.upenn.edu/cbe_sdr Part of the Biochemical and Biomolecular Engineering Commons Ho, Jeanne; Luchtan, Joseph; Perlman, Andrew; and Solute, Andrew, "BIOMASS OR GLYCEROL TO BIOFUELS" (2010). Senior Design Reports (CBE). 13. https://repository.upenn.edu/cbe_sdr/13 This paper is posted at ScholarlyCommons. https://repository.upenn.edu/cbe_sdr/13 For more information, please contact [email protected]. BIOMASS OR GLYCEROL TO BIOFUELS Abstract In the past decade, many advances were made towards the production of alternative fuels. Biodiesel is one such alternative fuel which has received much attention and research. However, its production also creates an abundance of crude glycerol, which is a waste product that has little value and is costly to purify. Therefore, a process which can utilize crude glycerol deserves analysis. In our project, a process was designed for the manufacture of various high value products from glycerol. This process used catalyst technology and reaction data from Virent Energy Systems, Inc. to convert crude glycerol feed into the products of hexane, butane, ethane, propane, and hydrogen. Our proposed process design yields a NPV of $238,317,900.00 and an IRR of 8.18%. Disciplines Biochemical and Biomolecular Engineering This working paper is available at ScholarlyCommons: https://repository.upenn.edu/cbe_sdr/13 Department of Chemical & Biomolecular Engineering Senior Design Report (CBE) University of Pennsylvania Year 2010 Biomass or Glycerol to Biofuels Jeanne Ho, Joseph Luchtan, Andrew Perlman, and Andrew Salute University of Pennsylvania Biomass or Glycerol to Biofuels Written by: Jeanne Ho Joseph Luchtan Andrew Perlman Andrew Salute Industrial Consultant: Mr. Stephen M. Tieri Faculty Advisor: Dr. John Vohs April 13, 2010 University of Pennsylvania Department of Chemical & Biomolecular Engineering University of Pennsylvania School of Engineering and Applied Science Department of Chemical and Biomolecular Engineering 220 South 33rd Street Philadelphia, PA 19104 April 13, 2010 Dear Mr. Fabiano, Dr. Vohs, and Stephen Tieri Enclosed is our proposed process design for the Biomass or Glycerol to Biofuels problem statement provided by Stephen M. Tieri of DuPont. Our solution includes four main parts: selection of raw materials, pretreatment, reactions, and separations. This process achieves the required 1MM gallons of product capacity specified by the problem statement. The following report details the process, the equipment needs and estimated costs, the utility requirements, and a detailed economic analysis. Our proposed process design yields a NPV of $238,317,900.00 and an IRR of 8.18%. Detailed economic analyses, including sensitivities to key input assumptions, have also been included and discussed. Feed and product costs and other potential risks to the long-term profitability of the process have also been addressed. Sincerely, Jeanne Ho Joseph Luchtan Andrew Perlman Andrew Salute Contents Abstract..........................................................................................................................7 Project Charter................................................................................................................9 Introduction..................................................................................................................12 Market Analysis............................................................................................................18 Pre-treatment.................................................................................................................22 Introduction...............................................................................................................23 Process Inputs............................................................................................................23 Pretreatment..............................................................................................................26 Comparison...............................................................................................................28 Process Background......................................................................................................30 Reactions...................................................................................................................31 Separations................................................................................................................35 Process Flow Diagram and Material Balance.................................................................39 Section 100: Reaction Train..........................................................................................50 Detailed Unit Descriptions.........................................................................................52 Section 200: Separations of CO2 and H2 ........................................................................57 Detailed Unit Descriptions.......................................................................................59 Sections 300 and 400: Tower Separations and Purification of Products...................62 Detailed Unit Descriptions.......................................................................................63 Section 500: Recycle Process ......................................................................................65 Detailed Unit Descriptions.......................................................................................67 Considerations for ASPEN Design................................................................................69 Aqueous Phase Reforming.........................................................................................70 Base-Catalyzed Condensation and Hydrodeoxygenation............................................76 CO2 Scrubbing with MEA.........................................................................................81 H2 Removal by PRISM Membrane............................................................................81 Difficulties Encountered in Separation Processes..........................................................82 Unit Specifications........................................................................................................85 Equipment Cost Summary...........................................................................................113 Energy Requirements..................................................................................................117 Utilities....................................................................................................................118 Heat Exchangers......................................................................................................122 Financial Analysis.......................................................................................................126 Introduction.............................................................................................................127 General Information................................................................................................129 Product Information.................................................................................................137 Chronology..............................................................................................................137 Equipment Costs......................................................................................................138 Raw Materials.........................................................................................................140 Byproducts..............................................................................................................140 Utilities....................................................................................................................140 Variable Costs.........................................................................................................141 Working Capital......................................................................................................141 Total Permanent Investment....................................................................................142 Fixed Costs..............................................................................................................142 Cost Summary.........................................................................................................144 Variable Costs and Fixed Costs...............................................................................148 Investment Summary and Working Capital..............................................................149 Cash Flows and Profitability Measures....................................................................150 Sensitivity Analyses....................................................................................................153 Variable Costs.........................................................................................................153 Product Price...........................................................................................................153 Inflation...................................................................................................................154
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